Safety in Design

Safety in Design provides practical guidance on integrating safety principles into every stage of process facility design — from concept development through commissioning and decommissioning. Drawing on lessons from major incidents, current standards, and best engineering practices, this primer introduces foundational concepts such as inherently safer design, fail-safe systems, safe operating limits, and human factors.

Written for engineers, designers, and safety professionals, the primer emphasizes risk-based thinking, multidisciplinary collaboration, and lifecycle responsibility. It also highlights emerging trends, including digital twins, ESG considerations, and climate resilience.

Whether you're involved in facility upgrades, new builds, or operational reviews, Safety in Design offers clear, actionable insights to strengthen the safety and integrity of your projects.

Design is the first and most crucial step in ensuring safety in the process and energy industries. A flawed design can embed hazards into a system that no amount of training or procedures can fully overcome.

Safety in Design (SID) aims to eliminate or reduce risk before construction or operations begin. Safety in design is achieved through multidisciplinary engineering reviews, hazard analyses and adherence to industry standards.

This Primer concludes with a ten-part Yes/No quiz. The quiz helps you understand your understanding of the principles of Safety in Design.

Table of Contents

Introduction
Core Concepts and Terminology
   Inherent Safety
   Process Hazards Analysis
   Safe Limits
   Fail-Safe Design
   RAGAGEP
Standards, Regulations and Authorities
Potential Pitfalls
Emerging Trends or Considerations
Conclusions
Knowledge Check: 10-Question Quiz
Questions
Answer Key

Here is the quiz.

Choose the best answer for each of the following questions.

1)      What is the primary goal of Safety in Design?
a)      Increase production
b)      Eliminate training needs
c)      Reduce operational costs
d)      Eliminate or control hazards before they occur

2)      What diagram provides the most detailed view of process equipment and control logic?
a)      BFD
b)      PFD
c)      P&ID
d)      Loop diagram

3)      Which standard governs safety instrumented systems in the process industry?
a)      API 520
b)      ASME Section VIII
c)      NFPA 30
d)      IEC 61511

4)      Which of the following is NOT a principle of inherently safer design?
a)      Substitute
b)      Complicate
c)      Minimize
d)      Moderate

5)      What is a common pitfall in process design?
a)      Performing a HAZOP
b)      Using current standards
c)      Relying only on procedures to manage risk
d)      Including multiple layers of protection

6)      What federal regulation governs Process Safety Management in the U.S.?
a)      40 CFR Part 68
b)      29 CFR 1910.119
c)      ASME B31.3
d)      ISO 14001

7)      What is a benefit of using digital twins in design?
a)      They reduce permit costs
b)      They simulate operating and emergency conditions
c)      They replace documentation
d)      They serve as legal compliance tools

8)      In which phase should hazard identification begin?
a)      After commissioning
b)      During maintenance
c)      During detailed design
d)      Before conceptual design

9)      What is the role of CCPS?
a)      Enforce OSHA standards
b)      Set environmental regulations
c)      Provide guidance and best practices for process safety
d)      Manufacture safety equipment

10)  Which of the following would most likely appear on a P&ID?
a)      Annual budget
b)      Pressure vessel design margin
c)      Relief valve and control loops
d)      Feedstock cost projections